Apparatus for reducing accumulation of waste and disposing of waste in carding machines

ABSTRACT

To reduce the liberation of dust and fly from the taker-in and adjacent areas of a carding machine, the usual taker-in cover is eliminated and a housing means, defining an expansion chamber of substantial volume in open communication with the upper portion of the taker-in, is positioned between the revolving flats, the taker-in feed roll, the taker-in and the main cylinder back plate, and air is continuously exhausted from the taker-in and the expansion chamber to relieve pressure incident to rotation of the taker-in while thereby removing any liberated dust and fly from the chamber.

United States Patent v Stewart 1 51 Dec. 26,1972

1541 APPARATUS FOR REDUCING 3,115,683 12/1963 Reiterer ..19/1 O7x ACCUMULATION OF WASTE AND DISPOSING 0F WASTE IN CARDING FOREIGN PATENTS 0R APPLICATIONS MACHINES 1,019,767 2/1966 Great Britain ..19 107 672,426 10/1964 Italy ..l9/l07 [721 mch'rd g? i f g 1,070,792 6/1967 Great Britain. ..19/107 Mersey, near "83 1,098,949 1/1968 Great Britain ..19 107 [73] Assignee: PIrks-Cramer (Great Britain) Ltd.,

Omharn, Lancashire Enghnd Primary Exam1ner-Dorsey Newton I '22] Filed Sept 14 1970 Attorney-Parrott, Bell, Seltzer, Park dc Gibson 1211 Appl. N6; 72,079 [57] ABSTRACT To reduce the liberation of dust and fly from the [30] Foreign n m priority Data taker-in and adjacent areas of a carding machine, the usual taker-in cover is eliminated and a housing 06!. 14,1969 Great Brltaln ..50,44s-/69 means, defining an expansion chamber of Substantial I volume in open communication with the upper por- [52] U.S. Cl ..19/107 tion of the takepin is positioned between the revolw [5]] Ila. Cl. g flats, the takepin e the takepin and the Fleld of Search main cylinder back p and i i continuouslyexhausted from the taker-in and the expansion chamber [56] References to relieve pressure incident to rotation of the taker-in UNITED STATES PATENTS while thereby removing any liberated dust and fly from the chamber. 3,537,144 l1/1970 King, Jr ..19/107 3,150,415 9/1964 Reiterer ..19/107 2 Claims, 3 Drawing Figures J I f 66 PATENTED EB I912 3 707, 020

' SHEET 1 UF 3 Sucmom Soura ce R\C.HARD GORDON STEWART ATTORNEYS PATENTED B I972 3,707,020

SHEET 3 OF 3 I. 1- R\CHARO GORDON STEWART ATTORNEYS APPARATUS FOR REDUCING ACCUMULATION F WASTE AND DISPOSING OF WASTE IN CARDING MACHINES Many different methods and forms of apparatus have been proposed heretofore to pneumatically remove dust, fly and other forms of fiber waste from various parts and areas of carding machines, especially cotton carding machines. The controlled removal of such fiber waste is a practical necessity,not only to improve the operation of the carding machines and the quality of the carded stock being produced, but to reduce danger to the health of the cardroom attendants. 1

Known prior art methods and apparatuses for pneumatic removal of fiber waste from cardingvmachines have been successful in largely eliminating the distribution of dust, fly and the like throughout the atmosphere surrounding the machines. However, among the more critical unsolved problems involved in the control of fiber waste is that of liberation or release of fiber waste from the taker-in and adjacent areas of the main cylinder and the revolving flats of a carding machine.

More specifically, it has been considered necessary heretofore to provide a close fitting arcuate cover over the taker-in of a carding machine to ensure the desired efficient operation thereof in transferring fibers from the taker-in feed roll to the main cylinder. Due to the high peripheral speed of the taker-in and the clothing or teeth thereon relative to the taker-in cover, high pressure builds up between the taker-in and the cover. Such pressure is relieved to some extent at the nip point between thefeed roll and the taker-in, however it takes the form of an undesirably high pressure waste-laden air stream which releases fibers from the stock circumscribing the taker-in, and which air stream is difficult to control. Also, some of such pressure built up is transmitted to the nip point between the taker-in and the main cylinder and flows upwardly between the usual cylinder back plate and the main cylinder to be released adjacent the nip of the main cylinder with the revolving flats and to flow upwardly between the flats per se.

Additionally, the pressure build-up between the taker-in and its cover prevents the release of substantial amounts of waste from the mote knives and grid bars of the screen beneath the taker-in so that the waste accumulates in the form of large tassels or elongate fibrous masses suspended from the mote knives and grid bars.

It is an object of this invention to provide an improved method and apparatus for reducing the liberation of dust and fly from the taker-in through elimination of the taker-in cover by providing housing means forming an air expansion area of substantial volume above and in direct communication with the upper portion of the takerin and extending between the taker-in feed roll and the main cylinder back plate, and wherein air is continuously exhausted from the upper portion of the taker-in and from the expansion area to relieve pressure incident to rotation of the taker-in while drawing any liberated fly and dust away from the taker-in.

The elimination of the taker-in cover prevents any substantial pressure build-up over the taker-in and, thus any waste-laden air flow created by the high speed rotation of the taker-in is of relatively low velocity and is readily exhausted from the expansion area by the applied suction. Also, the pressure released at the nip between the revolving flats and the main cylinder is greatly reduced. With elimination of the taker-in cover, the consequent elimination of-pressure build-up over the taker-in substantially eliminates the accumulation of waste fibers on the mote knives and grid bars of the screen beneath the taker-in, especially in those carding machines equipped with pneumatic dust extraction means beneaththe taker-in and the main cylinder.

As is well known, the revolving flats of a carding machine are generally close together as they move in cooperation with the main cylinder, but they are separated substantially as they pass around the supporting pulleys or wheels above the taker-in. The air pressure normally escaping between the upper edge of the cylinder back plate and the main cylinder produces a pulsing flow of air between the adjacent flats as they open or spread apart and thus produces a large amount of fine fly and lint which flows upwardly between the spread apart flats and into the space between the inner and outer runs of the flat series. Prior art block shaft suction tubes, which have heretofore extended above the lower pulleys of the card flats and between the inner and outer runs of the card flats, have been inefficient in the disposing of such fly.

As heretofore stated, the pressure released at the nip point between the flats and the main cylinder abovethe taker-in is greatly reduced, thus substantially reducing the problem of the flow of dust and fly upwardly between the spread apart flats. It is another object of this invention, however, to provide the aforementioned housing means withan arcuate cover extending forwardly from the rear wall means of the housing means and spaced a predetermined distance below the arcuate path of movement of the card flats thereabove. The front edge of the arcuate cover is spaced from the cylinder back plate, thus defining an air flow passage therebetween so that the suction applied in the air expansion area causes the dust and fly escaping from beneath the main cylinder and the upper edge of the cylinder back plate to flow downwardly through the passage and into the expansion area .to be exhausted therefrom. Additionally, a downward flow of air is induced between the spread apart flats and into the air expansion area. I

Some of the objects of the invention having been stated, other objects will appear as the description proceeds, when taken in connection with the accompanying drawings, in which;

FIG. 1 is a side elevation of the rear portion or feed end of a carding machine embodying the instant invention;

FIG. 2 is a fragmentary perspective view of the feed end of the carding machine showing the housing means.

of the instant invention with associated suction conduits or ducts connected thereto and broken away; and

HO. 3 is an enlarged fragmentary vertical sectional view through the taker-in, the taker-in feed roll, the main cylinder and-the adjacent portions of the revolving flats, and showing the improved housing means in association therewith.

Referring more specifically to the drawings, the numetal 10 broadly designates the frame of a cotton carding machine including lower side frame members 1 l supportingly respective arches 12 between which a driven main cylinder 13 is positioned. Textile fibers are directed from a lap roll 14 along a feed plate 15 and fed by. a driven feed roll 16 to a driven cylindrical taker-in l7 (FIG. 3). Taker-in 17 is provided with clothing of teeth 17a about the periphery thereof, as is usual, and forms a lower nip point 20 with. main cylinder 13. Beneath taker-in 17 are the usual mote knives 21 and an arcuate screen 22 including grid bars 23.

A conventional, solid, cylinder back sheet or plate 26 is positioned closely adjacent the path of travel of the clothing 13a on main cylinder 13 and extends upwardly from adjacent the lower nip 20 to a point adjacent an upper nip point 30 where the clothing 31a on driven revolving flats 31 moves upwardly into cooperating relation with clothing 13a on main cylinder 13. Opposing end portions of the card flats 31 are mounted on 32. However, the chains 32 are mounted on suitable rollers or sprocket wheels 33 spaced above taker-in 17, as a consequence of which the card flats are spread a substantial distance apart from each other during their arcuate movement downwardly'and then upwardly into cooperating relation with the main cylinder 13 above taker-in 17 The parts of the carding machine heretofore described are conventional and, therefore, a further detailed description thereof is deemed unnecessary. It is important to note, however, that the arcuate taker'in cover which usually overlies the taker-in 17 in closely spaced relation to the clothing 17a has been eliminated in accordance with this invention, thereby eliminating build up of high pressure above the taker-in and the consequent liberation or release of large amounts of dust and fly from the fibers entrained about the takerin, and also substantially eliminating the production of high velocity waste-laden air currents adjacent the nip between the taker-in 17 and the feed roll 16 on the one hand, and thenip between the taker-in 17 and the main cylinder 13 on the other hand, while the carding machine is in operation.

Substantial amounts of waste are released from the textile fibers being processed through a carding machine because of the high surface speeds of the main cylinder 13 and the taker-in 17, the relative surface speeds thereof, and the relatively slow surface speed of the revolving flats 31; The speed of the taker-in is varied according to the type of textile fibers being processed. By way of example, in a typical cotton carding machine having a main cylinder 13 about 50% inches in diameter including the wire card clothing 13a thereon, the main cylinder was rotated at a speed of about 300 revolutions per minute (rpm) or a surface speed of about 47,800 inches per minute, while the flats 31 moved at a surface speed of about 4 inches per minute. The carding machine was equipped with a taker-in 17 about 9.8 inches in diameter including the card clothing 17a thereon and the taker-in was rotated at a speed in the range of about 450. to about 900 rpm; i.e., at a surface speed of about l3,900 to about 27,700 inches per minute. In other words, the taker-in 17 was rotated at a speed of about 450 rpm in the processing of synthetic fibers, it was rotated at a speed of about 675 rpm in the processing of long staple or high quality cotton fibers, and it was rotated at a speed of about 900 rpm in the processing of relatively short staple cotton fibers. Thus, it can be appreciated that high velocity air currents are effected by such high surface speeds of the main cylinder and the taker-in throughout operation of a carding machine and, although the textile fibers are held by the teeth of the card clothing, dust and fly are nevertheless liberated or released from the main cylinder'and the taker-in, with substantially greater.

amounts of dust and fly being released from the takerin than are released from the main cylinder.

ln order that the aforementioned taker-in cover may be eliminated to thereby reduce the liberation or release of ,dust and fly from the taker-in andadjacent areas of the carding machine, and to also remove any liberated dust and fly which is nevertheless liberated or released from taker-in 17 and adjacent areas of the carding machine, I have provided housing means, broadly designated at 40, defining an air expansion area or chamber -of substantial volume open to the unobstructed upper portion of taker-in 17 and extending between feed roll 16 and cylinder back plate 26, and also extending between the exposed upper portion of taker-in 17 substantially all the way up to the revolving flats 31 spaced above taker-in 17.

As best shown in FIGS. 1 and 2, housing means 40 comprises a pair of opposing, spaced apart side walls 41, 42 whose forward portions are suitably removably secured to the outer surfaces of arches 12 of the carding machine frame 11, as by screws 43. Side walls 41, 42 straddle a lower portion of the revolving flats 31 above taker-in l7 and extend downwardly, spanning the distance between the card flats 31 and the upper portion of taker-in 17, and also having their lower'portions straddling the end frame portions at opposite ends of taker-in 17. The front portions of side walls 41, 42 are positioned adjacent opposite side edges of cylinder back plate 26. Suitable window openings, covered by suitable transparent panels 41a, 42a may be provided in the respective side walls 41, 42 to enable an attendant to inspect the interior of housing means 40 during operation of the carding machine.

The housing means 40 also comprises a rear wall means whose upper wall portion 45 is spaced a substantial distance rearwardly from cylinder back plate 26 so as to provide a large expansion area above taker-in 17. For convenience sake, however, the vertical upper wall portion 45 of the rear wall means is positioned within the vertical plane of taker-in l7 and its lower edge is connected to or formed integral with a downwardly and rearwardly inclined panel or rear wall portion 46 which is spaced substantially from the periphery of taker-in 17 and is provided with a resilient air seal 47 on the lower edge thereof yieldably engaging the periphery of and extending substantially throughout the length of feed roll 16.

The rear edges of side walls 41, 42 are preferably shaped to conform to the shape of the rear wall means 45, 46. In order to ensure that the lower edge of the inclined portion 46 of the rear wall means is positioned in close proximity to but in spacedrelation from the periphery of feed roll 16, the lower portion of each side wall 41, 42 is provided with an outwardly projecting tab 50 (FIG. 2) which is threadedly penetrated by an adjustment screw 51 whose lower end bears against the upper surface of a corresponding bearing block 52 in which reduced opposite ends of the taker-in 17 are journaled. As is usual, bearing blocks 52 are mounted upon the rear portions of the side frame members 11 of frame 10.

The housing means 40 is provided with an arcuate cover or curved shield plate 55 spaced a considerable distance above taker-in 17, and which is also spaced a relatively short distance beneath the arcuate path of travel of card flats 31 so as to form an air flow channel immediately beneath the lowermost portion of the path of travel of the card flats 31. The front edge of arcuate cover 55 terminates in substantially spaced relation rearwardly from cylinder back plate 26, thus defining an air flow passage between the front edge of cover 55 and the rear surface of cylinder back plate 26. The rear portion of cover 55 has a downwardly projecting flange 56 thereon which, as best shown in FIG. 2, is provided with a plurality of vertically extending longitudinally spaced adjustment slots 57 therethrough for the reception of suitable adjustment screws 60 for adjustably securing cover 55 to the upper vertical wall portion 45 of the rear wall means of housing means 40. Thus, the effective size of the channel defined between cover 55 and card flats 31 may be readily adjusted.

Means are provided for effecting a suction flow of air through the expansion area defined above the taker-in 17 by the housing means 40. Such suction flow of air continuously exhausts air from the exposed upper portion of the taker-in 17 and from the expansion area or chamber to relieve pressure incident to rotation of the taker-in and thereby reduce liberation of dust and fly from the textile material entrained on the taker-in. The suction flow of air also draws any dust and fly nevertheless liberated away from the taker-in, as indicated by the air flow arrows in FIG. 3. To this end, the housing side walls 41, 42 are provided with respective relatively large exhaust openings 61, 62 (FIGS. 2 and 3) therethrough which are located closely above the horizontal plane of the teeth 17a of taker-in l7. Corresponding ends of respective conduits or ducts 65, 66 are connected to the side walls 41, 42 for communication with the respective openings 61, 62.

Conveniently, duct 66 may extend along and adjacent the rear upper wall portion 45 of the housing rear wall means so that-both ducts 65, 66 mayextend along a common side of the carding machine, as shown in H0. 1, to a suitable suction manifold or source of suction indicated schematically at S in FIG. 1. Although suction ducts are shown connected to both side walls 41 42 of the housing means 40, it is to be understood that one of the exhaust openings 61 or 62 may be closed and only a single suction duct may be connected to the other of the side wall openings, if desired, without departing from the invention.

In any event, it is apparent that the suction source S will operate continuously during operation of the carding machine. The suction applied to the housing means 40 is, of course, greater than the pressure produced by the rotating taker-in so as to continuously exhaust air and any liberated dust and fly from the air expansion area defined by housing means 40. At the same time, the suction applied in the air expansion area causes the dust and fly escaping from between main cylinder 13 and the upper edge of cylinder back plate 26 to flow downwardly through the passage into the expansion area to be exhausted therefrom, and also causes a suction current of air to flow along the channel defined between arcuate cover 55 and the lower portions of the revolving flats 31 to further induce a downward flow of air therebetween, as opposed to the usual upward flow of air therebetween which has resulted, in part, from the upward flow of air emerging from between the upper edge of cylinder back plate 26 and main cylinder 13.

It has been found that the method and apparatus of this invention substantially reduces the amount of dust, fly and other waste released from the taker-in and also greatly reduces the amount of such fiber waste being released into the card room atmosphere during the carding operation, especially when carding cotton.

1n the drawings and specification, there has been set forth a preferred embodiment of the invention, and although specific terms are employed, they are used ina generic and descriptive sense only and not for purposes of limitation.

lclaim:

1. Apparatus for reducing the liberation of dust and fly in a carding machine and for disposing of dust and fly such as is liberated, said carding machine including a taker-in, a taker-in feed roll adjacent and rearwardly of the taker-in, a main cylinder forwardly of and forming a lower nip with the taker-in, a series of revolving flats spaced above the taker-in and forming an upper nip with the main cylinder, and a solid cylinder back plate proximal to the main cylinder and extending between said lower and upper nips; said apparatus comprising housing means defining an air expansion chamber of substantial volume above and open to the unobstructed upper portion of the taker-in and extending between said feed roll andsaid cylinder back plate such that a substantial portion of the upper surface of the taker-in is exposed to the interior of the expansion chamber, said housing means comprising spaced apart side walls straddling a lower portion of said revolving flats and extending downwardly and also straddling opposite ends of said taker-in, the front portions of said side walls being positioned adjacent opposite side edges of said back plate, rear wall means extending between and connected to said side walls, said rear wall means extending downwardly from a point spaced below said revolving flats and to a point rearwardly' of said takerin, means forming a substantial air seal between the lower edge of said rear wall means and said feed roll, a cover carried by said rear wall means, extending between said side walls and spaced a relatively short distance below said flats, the front edge of said cover being spaced from said back plate to define an air flow slot therebetween, and means connecting said housing means to a source of suction including a suction duct communicating with said chamber through at least one of said side walls between said taker-in and said cover whereby air is caused to flow from both of said nips and from the lower portions of the revolving flats into and through said chamber during operation of the carding machine while relieving pressure incident to rotation of the taker-in and thereby reducing liberation of dust and fly from textile material entrained on the taker-in to draw any liberated dust and fly away from the taker-in.

2. Apparatus for reducing the liberation of dust and fly in a carding machine and for disposing of dust and fly such as is liberated, said carding machine including a taker-in, a taker-in feed roll adjacent and rearwardly of the taker-in, a main cylinder forwardly of and forming a lower nip with the taker-in, a series of revolving flats spaced above the taker-in and forming an upper nip with the main cylinder, and a cylinder back plate proximal to the main cylinder and extending between said lower and upper nips; said apparatus comprising housing means definingan air expansion chamber of substantial volume above and open to the unobstructed upper portion of the taker-in and extending between said feed roll and said cylinder back plate'such that a substantial portion of the upper surface of the taker-in is exposed to the interior of the expansion chamber, said housing means comprising spaced apart side walls straddling a lower portion of said revolving flats and extending downwardly and also straddling opposite ends tending downwardly from a point spaced below said IMO revolving flats and to a point rearwardly of said takerin, means forming a substantial air seal between the lower edge of said rear wall means and said feed roll, a cover extending between said side walls and spaced a relatively short distance below said flats, said cover comprising a curved plate having a downwardly pro jecting rear portion thereon, means adjustably securing said rear portion of said curved plate to said rear wall means for vertical adjustment thereon whereby the distance betweenthe flats and the curved plate may be varied, the front edge of said cover being spaced from said back plate to define an air flow slot therebetween, and means connecting said housing means to a source of suction including a suction duct communicating with said chamber through at least one of said side walls between said taker-in and said cover whereby air is caused to flow from both of said nips and from the lower portions of the revolving flats into and through said chamber. 

1. Apparatus for reducing the liberation of dust and fly in a carding machine and for disposing of dust and fly such as is liberated, said carding machine including a taker-in, a taker-in feed roll adjacent and rearwardly of the taker-in, a main cylinder forwardly of and forming a lower nip with the taker-in, a series of revolving flats spaced above the taker-in and forming an upper nip with the main cylinder, and a solid cylinder back plate proximal to the main cylinder and extending between said lower and upper nips; said apparatus comprising housing means defining an air expansion chamber of substantial volume above and open to the unobstructed upper portion of the taker-in and extending betweeN said feed roll and said cylinder back plate such that a substantial portion of the upper surface of the taker-in is exposed to the interior of the expansion chamber, said housing means comprising spaced apart side walls straddling a lower portion of said revolving flats and extending downwardly and also straddling opposite ends of said taker-in, the front portions of said side walls being positioned adjacent opposite side edges of said back plate, rear wall means extending between and connected to said side walls, said rear wall means extending downwardly from a point spaced below said revolving flats and to a point rearwardly of said taker-in, means forming a substantial air seal between the lower edge of said rear wall means and said feed roll, a cover carried by said rear wall means, extending between said side walls and spaced a relatively short distance below said flats, the front edge of said cover being spaced from said back plate to define an air flow slot therebetween, and means connecting said housing means to a source of suction including a suction duct communicating with said chamber through at least one of said side walls between said taker-in and said cover whereby air is caused to flow from both of said nips and from the lower portions of the revolving flats into and through said chamber during operation of the carding machine while relieving pressure incident to rotation of the taker-in and thereby reducing liberation of dust and fly from textile material entrained on the taker-in to draw any liberated dust and fly away from the taker-in.
 2. Apparatus for reducing the liberation of dust and fly in a carding machine and for disposing of dust and fly such as is liberated, said carding machine including a taker-in, a taker-in feed roll adjacent and rearwardly of the taker-in, a main cylinder forwardly of and forming a lower nip with the taker-in, a series of revolving flats spaced above the taker-in and forming an upper nip with the main cylinder, and a cylinder back plate proximal to the main cylinder and extending between said lower and upper nips; said apparatus comprising housing means defining an air expansion chamber of substantial volume above and open to the unobstructed upper portion of the taker-in and extending between said feed roll and said cylinder back plate such that a substantial portion of the upper surface of the taker-in is exposed to the interior of the expansion chamber, said housing means comprising spaced apart side walls straddling a lower portion of said revolving flats and extending downwardly and also straddling opposite ends of said taker-in, the front portions of said side walls being positioned adjacent opposite side edges of said back plate, rear wall means extending between and connected to said side walls, said rear wall means extending downwardly from a point spaced below said revolving flats and to a point rearwardly of said taker-in, means forming a substantial air seal between the lower edge of said rear wall means and said feed roll, a cover extending between said side walls and spaced a relatively short distance below said flats, said cover comprising a curved plate having a downwardly projecting rear portion thereon, means adjustably securing said rear portion of said curved plate to said rear wall means for vertical adjustment thereon whereby the distance between the flats and the curved plate may be varied, the front edge of said cover being spaced from said back plate to define an air flow slot therebetween, and means connecting said housing means to a source of suction including a suction duct communicating with said chamber through at least one of said side walls between said taker-in and said cover whereby air is caused to flow from both of said nips and from the lower portions of the revolving flats into and through said chamber. 